Method of forming thick butt shingles



May 30, 1939. R, w READE Q 25,160,787

METHOD OF FORMINGTHICK BUTT SHINQLES Filed Sept. 30, 1955 1 2Shees-Sheet 1 May 1939- v R. w. B. READE 2,160,787

METHOD OF FORMING THICK BUTT SHINGLES Filed Sept. 30, 1935 2Sheets-Sheet 2 Patented May 30, 1939 UNITED STATES PATENT OFFICE METHODOF FORMING THICK BUTT SHINGLES Application September 30, 1935, SerialNo. 42,840

9 Claims.

This invention relates to roofing elements and more particularly toartificial roofing elements such as shingles, or strips simulating aplurality of shingles, in which the lower or weather por- 5 tion of theelement is of greater thickness than the upper or overlapped portion ofthe element, and also relates to a method of making such "thick buttelements in a desirable and expeditious manner. The invention will bebest un- 10 derstood by reference to the hereinafter description of theproduct and the method and machine for making the same, taken inconnection with the accompanying drawings, in which:

Figure 1 is a perspective view of a strip shingle element made inaccordance with the invention;

Fig. 2 is a plan view of a section of the surfaced and gritted web fromwhich the elements shown in Fig. l'are formed, it being noted that theweb is a three in one" widththat is, the web is of 20 a width equal tothe depth of three shingle elements-it being so dimensioned tofacilitate formation of the shingle elements in the most economicalmanner;

Fig. 3 is a vertical sectional view of the web shown in Fig. 6 taken onthe line 3-3.of the latter;

Fig. 4 is an elevational diagrammatic view of the various machineelements utilized in making the strip shingle shown in Fig. 1 inaccordance with the improved method, and it will be understood that,while the aforesaid machine elements are shown in fragmentary orillustrative style only, this figure is intended to be fully informativeof a machine for performing the desired service, all of the elementsthereof being sufficiently indicated as to function and the structuralelements being shown in proper sequence, to enable thoseskilled inthe-art to erect a machine for accomplishing the same purpose; and Figs.5 and 6 are fragmentary perspective views showing the manner in whichthe dams are arranged at two points in association with the materialfeeding spouts to apply the asphalt coating to the web in accordancewith the hereinafter detailed invention;

The just-referred-to machine for manufacturing the web; from which thestrip shingle shown in Fig. 1 is made, will first be described indetail.

m The web AB is understood to comprise roofing felt which has alreadybeen saturated as desired. This web is conducted over conveyor rolls andunder dams i I, which latter are of sufllcient 1ongitudinal extent andso fitted at their forward edges to the contour of coating rolls II asto insure that coating asphalt fed from spouts l3 will be applied to theweb only at the portions or along the lanes A, A, A, indicated in Fig.5. After passing the coating rolls l2, grits of any desired characterare fed onto the web from a hopper l4, whence the web passes under apressing roll l5 and is reversed to pass over a roll IS. The materialwhich has not adhered to the coating on the web, as well as thatdeposited on the zones 'not supplied with coating material from spouti3, falls back into hopper H to be used again.

The web next passes between presser rolls l'l-l 1, where the granuleswhich fell upon the web are pressed tightly into the coating on the 15already coated areas A, A, A. The web then passes under dams i8 arrangedsimilarly to the dams I l,so far as longitudinal extent andinterfitting' relation with rolls I9 is concerned,- at which pointspouts deliver coating asphalt l0 to the lanes or zones B, B which havenot been theretofore covered.

The asphalt supplied through spouts I3 is quite hot and of a lowviscosity. It is also of thin consistency so that the coating material 2applied at the first station or from the spouts l3 forms a coating ofminimum thickness on the zones of the web between the confining dams H-iI, i. e., on the lanes A, A, A. However, the coating asphalt suppliedthrough spouts 20 is of heavier consistency and is supplied at a lowertemperature, wherefrom the coating supplied to zones or lanes B, B ismuch thicker than that which has been supplied on lanes A, A, ,A.

After passing the last-referredeto dams and coating rolls IS, the web isled under one or more hoppers, generally referred to as 2 I-Zi, whencebrightly colored granules are deposited on the web, these latter,ofcourse, adhering only to those portions which are supplied with freshor last-applied coating asphalt, i. e., the zones or lanes .3, B.

While they form no part of the present invention, a number of hoppersarranged longitudinallyof the web are shown to indicate that the weatherportion of the web may be supplied with alternate variegated colorings.The illustrative showing comprises three longitudinally-arrangedhoppers,wherefrom three different colors may be laid on in any desired sequence,this latter depending entirely on the manner in which the hoppers arespaced, the sequence in which the hopper gates are opened, and the timeduring which said gates are opened.

The web then passes over additional drums and is finally led to cuttingknives or other devices. These latter are not shown, as any nowknownprocedure may be used in cutting these shingles. It is, however,necessary that they-be out along the lines 11-41., bb, shown in Fig. 2,it being noted that slots cc have been cut at desirable intervals in theweb before the aforesaid longitudinal cutting is performed. The stripsobtained from the last-mentioned cutting will carry a heavy or thickcoating at the lower or slotted edges of each strip. Thereafter theselatter are cut transversely to make the strip shingles shown in Fig. 1.

While the thick and thin portions of the coating are above described asbeing applied progressively along the path of travel of the web,

this invention may also be of value in a process where one applies thethick and thin coatings in simultaneous side-by-side relation and, by sodoing, insures the production of a web having the two coatings ofvarying thickness thereupon to the same degree as hereinbeforedescribed.

While the invention herein contemplated has been described in oneembodiment for purposes of illustration, the description is not to betaken in a limiting sense, but the invention is to be limited only bythe scope of the appended claims.

I claim:

1. The method of forming a thick butt shingle which comprises applying aplastic coating of one thickness to one portion of a foundation element,applying only to a portion of said element left unsurfaced by saidcoating a plastic coating of different thickness, and surfacing saidplastic coatings with grits.

2. The method of forming a thick butt shingle which comprises applying aplastic coating of one thickness to the weather portion of said shingleand applying a plastic coating of a lesser thickness to a portion ofsaid shingle left uncoated by said first coating, said coating of lesserthickness being confined entirely to said portions left uncoated by saidfirst coating.

3. The method of forming a thick butt shingle which comprises forming a.coating of varying thickness on the broad surface of a web by applyingplastic coating materials of diverse consistencies to different portionsof said broad surface of said web.

4. The method of forming a thick butt shingle which comprises forming acoating of varying thickness on the broad surface of a web by applyingplastic coating materials of diverse consistencies to different portionsof said broad surface of said web, said diversely characterized coatingmaterials being permitted to merge at the junctions ofthe areas coveredthereby to comprise an integral coating over' the entire broad surfaceof the web.

5. The method of forming a thick butt shingle which comprises supplyinglongitudinally of a foundation web a plastic coating of one thicknessalong selected areas of said web and thereafter supplying anotherplastic coating of different thickness along only those portions of theweb left unsurfaced by the firstcoating.

6. The method of forming a thick butt shingle which comprises supplyinglongitudinally of the broad surface of a foundation web a plasticcoating of one thickness and consistency along selected areas thereofand supplying another plastic coating of different thickness andconsistency along the areas of said broad surface left unsurfaced bysaid first coating.

7 The method of forming a. thick butt shingle, having the weatherportion thereof of one thickness and the overlapped portion thereof ofanother thickness, which consists in applying plastic coatings ofdifferent thicknesses and viscosities along the weather and overlappedportions of said shingle, said different coatings being respectivelyapplied to separate portions of said shingle in nonoverlapping relation.

8. A method of forming a thick butt shingle having the weather portionthereof of one thickness and the overlapped portion thereof of anotherthickness, which method consists in applying plastic coatings ofdifferent thicknesses along said weather and said overlapped portions ofsaid shingle, the coating applied to said overlapped portion beingconfined entirely to said overlapped portion and being at an elevatedtemperature to provide a low viscosity during application, and thecoating applied to said weather portion being at a lower temperature toprovide a high viscosity during application.

9. A method of forming a thick butt. shingle which comprises applying aplastic coating to selected portions only of a. foundation element,applying a layer of grits to the surface of said element, reversing saidelement to remove said grits from the uncoated portions thereof,thereafter applying only to'said uncoated portions of said element aplastic coating of a different thickness, and applying another layer ofgrits to the sur face of said foundation element, said first layer ofgrits embedded in said first coating preventing the adherence of saidsecond layer of grits to said selected portions.

RALPH W. B. READE.

